Project Overview

This project documents the development of metal 3D printing using wire arc additive manufacturing. The process involves layering welds to build solid structures, using six-axis robotic systems to print steel and aluminum components. The focus of the work is to establish a reliable, repeatable procedure that defines the programming and weld settings required to produce complete parts from start to finish.

The project also explores how to achieve consistent material strength and mechanical performance in printed components. By refining the process, the team aims to produce parts that meet or exceed the properties of traditionally manufactured materials. This includes the potential to create hollow structures for weight reduction while maintaining durability, as well as tailoring material characteristics for specific industrial applications.

Client

Conestoga College - School of Engineering & Technology

Services

Project Coordination

Directing & Shooting

Video Editing

Credits

Project Lead: Joe Barnes

Outcomes

The work demonstrates a viable approach to robotic metal 3D printing with clear potential for industrial use. It establishes a foundation for repeatable production while highlighting opportunities for lighter, stronger, and more customizable components. The project also identifies room for further development across different materials and applications, supporting broader adoption of the technology as it becomes more efficient and accessible.